Modular Housing Unit

ABSTRACT

A building constructed of pre-formed profiles made from a composite plastic and wood chip material uses standardized profiles for floor, wall, truss, and roof members. The wall profiles are connected using H shaped connector profiles and interfitting notches along with standard fasteners. The entire structure is reinforced by a series of anchor bands passing over roof trusses and opposing walls.

REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of co-pending application Ser. No. 11/555,475 filed Nov. 1, 2006 which is a continuation in part of application Ser. No. 10/861,112 filed Jun. 4, 2004, which in turn is a continuation of application Ser. No. 09/171,910 filed May 13, 1999, now U.S. Pat. No. 6,929,841, which in turn is based on PCT application PCT/NL95/00153 filed Apr. 27, 1995, now WO 96/34045, all of which are relied on and incorporated herein by reference. This application is also a continuation in part of co-pending application Ser. No. 11/532,271 which is a continuation-in-part of PCT application PCT/NL2005/00198 filed Mar. 16, 2005 which is relied on and incorporated herein by reference.

INTRODUCTION AND BACKGROUND

The invention relates to a building and method for making the same wherein substantially all of the components are made from a plastic-based composite product which comprises at least partially of a plastic in which a material consisting substantially of particles is homogeneously embedded, which particles have tensile strength in at least one principal direction. The materials are made substantially in accordance with U.S. Pat. No. 6,929,841 or U.S. Pat. No. 7,241,484 or U.S. Pat. No. 7,445,830 each of which is incorporated herein by reference.

SUMMARY OF THE INVENTION

It is an object of the invention to provide a building made from a plastic-based composite product which can be manufactured at low cost but which nevertheless meets high standards which may be required in respect of various properties. Such properties can relate for instance to high mechanical properties, weather resistance, non-ageing properties and the like. Another object of this invention is an apparatus for carrying out the aforesaid method. The plastic-based composite material having a synthetic matrix and incorporated therein wood particles used for purposes of making the structural profiles described herein is described in detail in U.S. Pat. No. 6,929,841, granted Aug. 16, 2005, the disclosure of which is relied on and incorporated herein. The building is made almost completely from structural profiles made from these materials. Such structural profiles have a wood-like appearance and can have sufficient strength for various uses. They are easy to assemble into a wall.

The wall elements according to the invention are strong and do not need to be filled with concrete or other substances in order to provide a sufficiently strong wall. Instead, if so desired, they can be filled with an insulating material, such as insulation foam, so that the wall elements acquire increased sound-insulating and/or heat-insulating properties. A further advantage is that the presence of wood fibers provides the wall or the building with a finished wood-like appearance, as a result of which covering layers do not need to be provided. The particles are embedded in the synthetic material and do not protrude from the surface. Should a rough surface or a decorated surface be wanted, however, then this may optionally be achieved by brushing or embossing. Many types of surface modifications are possible to give the panels any type of desired appearance.

Moreover, the presence of wood fibers will result in a natural graying of the surface of the profiles when exposed to outdoor conditions. The wall elements of the invention can also be painted with any kind of paint due to the high content of wood fiber and low moisture absorption of the composite material resulting in an extremely good adhesion and long lasting paint durability.

A wall constructed with hollow profiles according to the invention has a minimum number of joints. The wall profile may comprise several parallel hollow chambers or channels. The first and second edges which normally define the top and bottom of a wall profile are preferably formed so that adjacent panels will fit into each other vertically. The first edge may form a narrowed protrusion and the second edge an accommodation space for the first edge of an adjacent similar wall element, wherein the recess is disposed in the second edge.

The wall elements of the invention are grease resistant and grease spots are easily removed. The panels also have good scratch resistance since they are far harder than natural wood and especially WPC composites. The panels of the present invention can be pressure washed whereas natural wood can be heavily damaged. In order to give room for expansions, particularly as a result of moisture absorption, the first and second coupling members may be provided with a dilatation provision or expansion joints. Thus, water tight constructions can be made by assembling a plurality of the wall elements which will undergo some moisture absorption and swell, thereby forming a tight connection between adjacent elements.

The invention will be elucidated on the basis of an exemplary embodiment shown in the attached drawings, in which:

FIGS. 1A to 1G are perspective views of various profiles used in constructing a building in accordance with the present invention;

FIGS. 2A and 2B show a truss profile in end view and side elevation respectively;

FIG. 3A to 3E shows a sequential process for constructing a building using the profiles according to the invention; and

FIG. 4 shows and H connector profile.

DETAILED DESCRIPTION OF INVENTION

Referring to the drawings for a clearer understanding of the invention it will be seen in FIGS. 1A to 1F that various profiles of building components are used in the present invention. The profiles in FIG. 1A to 1F are made by extrusion from a composite of a thermoplastic synthetic material, particularly polyolefin, such as polyethylene or polypropylene, or PVC or polycarbonate. The preferred material is polypropylene. In the polypropylene matrix wood particles comprising wood fibers or other cellulose-containing particles are embedded. The content of wood particles is more than 50% by weight, preferably more than 70% by weight, more preferably between 70-80% by weight, and the content of polypropylene is complementary thereto, preferably 20-30% by weight. A particularly preferred ratio is approximately 72/28% by weight. Such a material is available from the applicant under the trademark TECH-WOOD.RTM. and has proven its strength, rigidity and durability. The material has a wood-like appearance and after extrusion already has a smooth surface. The material has a E-modulus of at least 4000 MPa, preferably 4000-8000 MPa. The product according to the invention can have a thermal expansion similar to that of natural wood and also has a similar strength and stiffness with a comparatively great toughness and excellent cracking strength. The product can display fire characteristics which, by making use of environmentally-friendly additives, can be at least the equal of the fire characteristics of normal wood and which when it burns may not produce any more smoke and harmful substances than does normal wood. At a specific density of 1150-1250 kg/m³, the process and the required raw materials and additives may not exceed the price of normally processed wood.

Further increase of the constructional strength and rigidity of the profile can be achieved when continuous reinforcement elements are extruded along in the panel for accommodation in the composite material, extending in the direction of extrusion. The E-modulus can then be considerably higher, between 6000-12000 MPa.

The profiles shown in the FIGS. 1A to 1F and 2A and 2B are made of the thermoplastic-wood particle material described herein above. The method of manufacturing has been described in the United States Patents referenced herein above which are commonly owned by the same assignee as the instant application. The profile shown in FIG. 1A is the primary building element used in construction of residential and other utilitarian buildings in accordance with the present system and is used as an exterior wall profile, interior wall profile, and can be used as a flooring profile. As may be seen the wall profile 11 is preferentially formed with a plurality of internal gussets 12 extending transversely of a pair of opposed panels 13 and 14, thereby forming a plurality of tubes within wall profile 11. Opposed panels 13 and 14 extend below the lower most gusset 12 to form flanges 13 a and 14 a defining an downwardly opening channel bisected by a downwardly extending rib 16. On an opposite edge of wall profile 11 panels 13 and 14 are continued by extensions 13 b and 14 b spaced apart by a reduced distance and connected by an integrally formed plate 17 to form a mating protrusion which fits within a channel formed by the flanges of a superjacent wall profile to form part of a vertical wall. Wall profiles 11 weigh between about 3.2 and 3.8 pounds per linear foot and may be fabricated in any length desired. It is contemplated that they will be fabricated in 3, 6, 9 and 12 foot lengths and will have a weight of about 3.5 pounds per linear foot, thus, each wall profile 11 can be easily lifted into place to form a wall manually by a single worker or even more easily by two workers. Thus, utilizing the profiles of the present invention allows the construction of buildings without any specialized tools.

The connector profile 21 shown in FIG. 1C is an H connector which is used to join wall profiles 11. Connector profile 21 has a weight of between about 1 and 2 pounds per linear foot, preferably about 1.8 pounds per linear foot, and may be used to join wall profiles length wise to extend the run of a wall built from such profiles. Such profiles may also serve as framing elements around doorways and windows. As may be seen the profile may have an open area in its web 22 to accommodate electrical wiring or plumbing which may be installed within the tubular cavities of wall profile 11. If sized appropriately H connector profiles 21 may be inserted lengthwise into adjacent wall profiles to connect the two profiles. The channel profile 25 shown in FIG. 1B is a longitudinal channel member which can be used for terminating a wall, such as an interior wall or the end of an exterior wall at a corner when joined with another wall as hereinafter described. This terminal profile has a weight of about 1.5 to 2.5 pounds per linear foot, preferably about 1.9 pounds per linear foot FIG. 1D shows an exemplary purlin profile 45 with continuous reinforcement elements 46 incorporated therein for increasing the rigidity and the strength.

The profiles shown in FIGS. 1D, 1F and 1G are used in roofing the house as are the truss profiles shown in FIGS. 2A and 2B. Rafter profile 31 is substantially similar to wall profile 11, however the flanges 13 a and 14 a are not necessary in rafter profile 31. Additionally, the protrusion along the top of rafter profile 31 is preferentially routed out at spaced apart intervals to receive purlin profiles 45 which are shown in FIG. 1D. Rafter profiles are joined together with purlin profile posts and struts to form trusses 35 which sit atop the walls of the building. The purlin profiles serve the same function as traditional wooden purlins and weigh less than one pound per linear foot. Roof profiles 33 and 34 as shown in 1F and 1G may be corrugated vented air profiles or batten board profiles and generally weigh between about 2.5 to 3.5 pounds per linear foot and more particularly about 1.95 pounds per linear foot.

The profile shown in FIG. 1E is a post profile 50, used to support a truss or beam where no wall is available for support. Typically this profile will have a weight of about 2 to 2.5 pounds per linear foot and more particularly about 2.2 pounds per linear foot.

The profiles will be described in greater particularity with respect to the construction of an exemplary building. It is ostensibly noteworthy to mention that the heaviest of the profiles weighs less than 4 pounds per linear foot, thus 8 to 12 foot sections of the profile would weigh less than 50 pounds and could be easily managed by laborers without sophisticated lifting equipment.

Referring to FIG. 3A, a dwelling floor plan is shown for use in providing low income housing with profiles made from our composite is shown in a perspective view. The internal configuration could be modified to a three bedroom floor plan shown including a living/dining room, bathroom, and porch. Any suitable foundation may be used and wall profiles 11 may be interconnected horizontally to form a floor for the building. It is contemplated that the entire building material needs of the house would be partially precut, then palletized for shipment and storage so that the palletized materials could be delivered to the construction site for rapid and easy construction of the house.

As seen in FIG. 3A, the external walls are outlined by a bottom row of wall profiles 11. At the corners of the external walls one of the intersecting wall profiles is cut out to form downwardly opening notches such that the notched wall may be placed across the perpendicular adjacent wall profile to connect the two members. Intermediate the corners, wall profiles of varied lengths are connected by H-connection profiles as shown in FIG. 4. Transverse inside walls that are intended to terminate at the outer wall may also have the notched construction as described at the intersection with the outer wall. As hereinabove described the wall profiles have an upper longitudinal protrusion which fits into a downwardly opening channel formed on a superjacent wall profile. Thus the walls may be built by sequentially layering the wall profiles along the wall boundary interlocking each row to the adjacent rows with H-connection profiles and the mating channel and protrusion members. It will be appreciated that the length of the profiles in the walls should be varied so as to avoid having a substantial number of wall profile ends aligned vertically. Indeed the structure of the H connector requires that two H connectors not be aligned vertically. Walls may also be terminated with the profile shown in FIG. 1C which can also be used to frame windows and door ways.

As shown in FIG. 3D et seq, when the walls have been raised to the desired height truss profiles are set atop the wall profiles. It will be understood that the wall profile and truss profiles will be cooperatively notched for interlocking engagement. Stabilizer straps 55 are routed over at least two of the truss profiles and anchored on opposite sides of the building to add structural stability to the building and enhance the mechanical connectors such as bolts, rods, nails and plates that may also be used in fastening the profiles to one another.

As shown in FIG. 3I the roofing panels are the last to be attached to the purlins using conventional fasteners.

The material characteristics of the panels used in the present invention are illustrated in the patents incorporated herein by reference. Addition of 10% glass or flax fiber with a length of 4 mm and L/D 150 to 400 gives values about 25% higher than shown above.

Another embodiment is characterized by the addition of at least one additive for obtaining desired properties, which additives can be is added to the compounder during blending, heating during manufacture of the agglomerate The said desired properties of the skin surfaces may relate for instance to the adherability of paint, lacquer and glue.

The use of coloring agents or pigments in the mass can provide the advantage that a uniform product is obtained. Further, an additional coating can be applied to the visual side of the product profiles. Such a coating can have, for example, an extra-stable color, an increased UV-resistance or resistance to dirt and weather influences.

The profiles according to the invention can be worked with normal tools and normal wood processing machines. In the usual manner of wood, it can be nailed, sawn, screwed, glued, painted and lacquered. Accordingly, buildings in accordance with the present invention can be fabricated without the need for highly technical tooling and procedures, thus lending itself to low cost housing for developing markets. Further, the buildings and any waste products not used therein in practicing the invention are better suited for recycling after use than natural wood and are superior to wood in respect of moisture absorption, rotting and mildew resistance, termite resistance, paint durability and non-slipperiness.

Further variations and modifications of the foregoing will be apparent to those skilled in the art and are intended to be encompassed by the claims appended hereto. 

1. A building, having exterior and interior walls and a roof, made from a plastic-based composite of a plurality of wood particles uniformly blended into a thermoplastic polymer, wherein a. said exterior walls are made from a plurality of wall profiles extruded as generally elongated rectangular tubular members having first and second opposite longitudinal edges extending in profile direction, which longitudinal edges are provided with a first and second coupling member, respectively, wherein said first coupling member defines an accommodation recess space for receiving a protrusion formed on a second coupling member at a second longitudinal edge of another wall profile when assembled therewith, and b. said roof is made from a plurality of roof profiles extruded from said plastic-based composite having interlocking couplings formed on each longitudinal edge thereof, c. said roof supported by said walls and a plurality of trusses made from a plurality of truss profiles extruded from said plastic-based composite, wherein said plurality of wall profiles and truss profiles interlock and are secured by straps extending from the bottom of one wall over selected ones of said plurality of said truss profiles to the bottom of an opposite wall.
 2. A building as defined in claim 1 wherein said exterior walls comprise multiple wall profiles oriented with said first coupling member facing downwardly with each wall profile coupled to at least one superjacent wall profile until said exterior walls reach a predetermined height, wherein selected ones of said exterior walls are perpendicular and interlock at each intersection of said exterior walls with each other.
 3. A building as defined in claim 2 further comprising at least one interior wall formed from the same profiles as said exterior walls with said profiles oriented transversely to at least one exterior wall and interlocking with said at least one exterior wall.
 4. A building as defined in claim 2 wherein each of said wall profiles weighs between about 3.2 and 3.8 pounds per linear foot.
 5. A building as defined in claim 4 wherein each of said wall profiles weighs about 3.5 pounds per linear foot.
 6. A building as defined in claim 2 wherein each of said wall profiles is no greater than twelve feet long.
 7. A building as defined in claim 1, wherein each profile in said exterior walls is sufficiently light weight to permit placement on a subjacent profile by hand.
 8. A building as defined claim 2 wherein at least one exterior wall has a length equal to or greater than the length of two wall profiles such that said wall profiles are connected end to end to form said at least one exterior wall by interstitial connecter profiles extruded from said plastic-based composite.
 9. A building as defined in claim 8 wherein each of said wall profiles weighs about 3.5 pounds per linear foot and each of said connecter profiles weighs between about 1.0 and 2.0 pounds per linear foot.
 10. A building as defined in claim 9 wherein each of said plurality of roof profiles weighs between about 1.5 pounds per linear foot and 2.5 pounds per linear foot.
 11. A building as defined in claim 2, wherein each profile in said exterior walls is sufficiently light weight to permit placement on a subjacent profile by hand.
 12. A building as defined in claim 2 wherein said truss profiles are supported on said exterior walls and interlock therewith.
 13. A building as defined in claim 12 wherein said plurality of truss profiles support a plurality of purlin profiles extruded from said plastic-based composite.
 14. A building as defined in claim 13 wherein each of said wall profiles weighs between about 3.2 and 3.8 pounds per linear foot, each of said plurality of roof profiles weigh between about 1.5 and 2.5 pounds per linear foot, and each purlin profile of said plurality of purlin profiles weighs less than about 1.0 pounds per linear foot.
 15. A building as defined in claim 1 wherein exterior and interior walls and a roof are made from a plastic-based composite of a plurality of wood particles uniformly blended into a thermoplastic polymer such that each of said walls and roof may be shredded and reused for manufacturing of profiles for use in similar buildings.
 16. A building as defined in claim 7 wherein said profiles may be affixed to each other with threaded members inserted with a hand tool.
 17. A building as defined in claim 7 wherein said profiles forming said walls and roof are designed for assembly into said walls and roof by hand by unskilled laborers.
 18. A building as defined in claim 1 wherein the weight of said building is about 10000 pounds/1000 square feet.
 19. A building as defined in claim 1, wherein the average weight of said building is about 10 pounds per square foot. 